Powder forging method of aluminum alloy powder of high proof stress and toughness

Abstract: Either aluminum alloy powder or a green compact thereof is prepared wherein: (1) the composition formula is Aℓ 100-a-b Fe a X b where a and b in atomic % are 4.0 ≦ a ≦ 6.0, 1.0 ≦ b ≦ 4.0, where X is at least one type of alloy element selected from Y and Mm (mish metal); or (2) the composition formula is Aℓ 100-a-b-c Fe a Si b X c , where a, b and c in atomic % are 3.0 ≦ a ≦ 6.0, 0.5 ≦ b ≦ 3.0, and 0.5 ≦ c ≦ 3.0, where X is at least one type of alloy element selected from Ti, Co, Ni, Mn and Cr, and both (1) and (2) include an amorphous phase of at least 1% by volume. At least either the aluminum alloy powder or the green compact thereof is heated at an increasing temperature rate of at least 80°C/min. to a predetermined temperature of at least 560°C and not more than a temperature at which a liquid phase is contained 10% by volume. At least the aluminum alloy powder or the green compact thereof is powder forged at the predetermined temperature. As a result, an aluminum alloy superior in static strength and dynamic strength can be produced.

Description: The present invention relates to a powder forging method for producing aluminum (Aℓ) alloy powder of high proof stress and toughness that can be applied to components such as engine components of cars in which toughness is required. More particularly, the present invention relates to a powder forging method for producing an aluminum alloy superior in dynamic strength. Description of the Background Art From the US-A-4,435,213, a method for compacting an aluminum alloy powder and shaping the same into a useful article including heating the compact rapidly by induction heating techniques is known. The maximum heating rate is 45°C/min, and the forging is performed at 260 - 454°C. A method of powder forging by subjecting an amorphous phase to a heat treatment is proposed in Japanese Patent Application No. 4-77650 (filed March 31, 1992) (Japanese Patent Laying-Open No. 5-279767) by the inventors of the present application. A method of heating atomized powder of Aℓ-Fe-Y type to obtain aluminum in a nano structure (a structure of grains or precipitates in nm unit) is disclosed in Japanese Patent Laying-Open No. 2-274834. Atomized powder of Aℓ-Fe-Si-X type (at least one of X=Ti, Co, Ni, Mn, and Cr) is proposed in Japanese Patent Application No. 4-113712 (filed May 6, 1992) (U.S. Patent No. 5,312,494) by the inventors of the present application. The above-mentioned Japanese Patent Laying-Open No. 4-77650 proposing a powder forging method provides only the description of "at least the glass transition temperature (approximately 250-300°C in general) for the forging temperature. The highest temperature described in the embodiment thereof is 550°C. The inventors of the present application carried out various experiments according to this description, and found out that, by a heating process up to the temperature of 550°C, favorable values can be obtained for static strength by a tensile test or the like, but not for dynamic strength such as the Charpy impact values. The alloy disclosed in the above-mentioned Japanese Patent Laying-Open No. 2-274834 and Japanese Patent Application No. 4-113712 is noteworthy of having superior static strength and dynamic strength. However, this strength has been assessed only for an alloy that is solidified by extrusion. The inventors of the present application have found out that the static strength is superior but the dynamic strength is not sufficient when this alloy is powder-forged at the general heating temperature of 450-550°C. A powder forging method of producing an aluminum alloy that satisfies both the static strength and the dynamic strength was not yet achieved. SUMMARY OF THE INVENTION An object of the present invention is to provide a powder forging method of producing an aluminum alloy having superior static strength and dynamic strength. In view of the foregoing, the inventors of the present application have taken intensive research efforts to obtain an aluminum alloy having superior static strength and dynamic strength by a forging method with a predetermined alloy composition including aluminum. This method is characterized in that forging is carried out after the forging temperature is rapidly raised to a high level. According to an aspect of the present invention, a powder forging method of aluminum alloy powder of high proof stress and high toughness includes the following steps. At least either aluminum alloy powder or a green contact thereof is prepared wherein the general formula of the composition is: Aℓ 100-a-b Fe a X b where a and b in atomic % are: 4.0 ≦ a ≦ 6.0, 1.0 ≦ b ≦ 4.0, and where X is at least one alloy element selected from Y (yttrium) and Mm (mish metal), and an amorphous phase is contained at least 1% by volume. At least either the aluminum alloy powder or the green compact is heated at an increasing temperature speed of at least 80°C per minute to a predetermined temperature of at least 560°C and not more than a temperature at which a liquid phase is contained 10% by volume. At least either the aluminum alloy powder or the green compact is powder-forged at that predetermined temperature. In a powder forging method of aluminum alloy powder of high proof stress and high toughness according to a preferable aspect of the present invention, the predetermined temperature is at least 600°C and not more than a temperature at which a liquid phase is contained 10% by volume. According to a further aspect of the present invention, a powder forging method of aluminum alloy powder of high proof stress and high toughness includes the following steps. At least either aluminum alloy powder or a green compact thereof is prepared wherein the general formula of the composition is: Aℓ 100-a-b-c Fe a Si b X c wherein a, b, and c in atomic % are: 3.0 ≦ a ≦ 6.0, 0.5 ≦ b ≦ 3.0, 0.5 ≦ c ≦ 3.0, and where X is at least one alloy element selected from Ti (titanium), Co (cobalt), Ni (nickel), Mn (manganese) and Cr (Chromium), and an amorphous phase is contained at least by 1% by volume. At least either the aluminum alloy powder or the green contact thereof is heated at an increasing temperature speed of at least 80°C per minute to a predetermined temperature of at least 560°C and not more than a temperature at which a liquid phase is contained 10% by volume. At least either the aluminum alloy powder or the green compact thereof is powder-forged at that predetermined temperature. According to a preferable method of powder forging aluminum alloy powder of high proof stress and high toughness, the predetermined temperature is at least 580°C and not more than a temperature at which a liquid phase is contained 10% by volume. The present invention is characterized in that high static strength of a powder forged product can be maintained and the dynamic strength thereof improved according to the above-described alloy composition. More specifically, the present invention is characterized in that forging is carried out with powder rapidly heated to a high forging temperature that was not used in a conventional powder forging method in order to improving bonding of powder in powder-forging. In a conventional alloy, a liquid phase becomes distinguishable from approximately 530°C. In such a conventional alloy, forging is carried out at the temperature of approximately 490-520°C. A powder forging method differs from an extrusion method in that a great shear force is not exerted upon the powder. Therefore, an oxide coating (Aℓ 2 O 3 ) on the surface of a powder particle which prevents the bonding of powder particles with each other cannot be fractured and disrupted by such a shear force in the powder forging method. Conventionally-used air atomized powder particles have a surface oxide film generated in the liquid phase of high temperature, and the eventual configuration becomes distorted and uneven due to heat shrinkage between the internal metal and the surface oxide coating. Therefore, air atomized powder particles have the oxide coating easily fractured and disrupted as a result of great local shearing deformation caused by a simple compression deformation. Hard particles such as intermetallic compounds of Si (silicon) or Fe (iron) and Aℓ (aluminum) of approximately 1-5µm are dispersed in the material powder used for conventional powder aluminum. These hard particles serve to fracture and disrupt the surface coating of the particles at the time of deformation of powder forging. It is often not possible to obtain sufficient bonding between powder particles in powder forging with the above-described amorphous powder used in the present application or the aluminum powder of high proof stress and high toughness including an amorphous phase of at least 1% by volume. This is because: (1) the powder particles have a sphere-like configuration due to being solidified rapidly in an inert gas, so that a great local deformation does not occur with a simple compression; (2) the powder particles are not easily deformed during powder forging due to its hyperfine structure of amorphous or near amorphous with high strength; (3) a great local deformation does not occur during deformation since the structure is hyperfine and uniform; and (4) the volumetric shrinking of the amorphous phase occurring during crystallization due to heating prevents the destruction of the surface oxide coating caused by thermal expansion of the internal metal during a heating step prior to forging. In forming amorphous according to a molten metal rapid cooling method such as high pressure gas atomization or a solid phase reaction method such as mechanical alloying, an alloy element is used for improving the amorphous formation performance. This alloy element is known to have the features such as: (a) the atomic dimension ratio to aluminum which is a matrix is not more than 0.8; and (b) the interatomic interaction with aluminum is negative, and the mixing enthalpy is high. All alloy elements exhibiting the features of (a) and (b) cannot easily form a solid solution with the aluminum matrix, and has low migration. Such an alloy element functions to raise the melting point of an aluminum alloy rather than lowering the melting point. Because an aluminum alloy including such an alloy element will not fuse even when heated to a high temperature, and because the structure is not easily roughen, forging at a higher temperature is possible. A forging process at a higher temperature offers the following effects. (i) The water of crystallization of the surface oxide coating is more completely removed, so that the coating becomes brittle. A general surface structure of an aluminum alloy is set forth in the following. There is a crystalline alumina called γ alumina at the surface of an aluminum base. An alumina layer including water of crystallization exists at the surface of the crystalline alumina. On the surface of the alumina layer, water of absorption is present. Although alumina including water of crystallization has a certain degree of ductility, this ductility is lost when the alumina has the water of crystallization removed by heat degassing, so that a slight deformation will cause fracture. (ii) Increase in the range of heating temperature increases the difference in the thermal expansion between the oxide coating and the internal metal, whereby fracture and disruption of the coating becomes significant. (iii) A heating process to a higher temperature facilitates the softening and deformation of the powder particles. Depending upon the composition, the forging temperature at which the above-described effects of (i), (ii), and (iii) appear is at least 560°C, preferably at least 600°C, with the composition of the one aspect of the present invention. Furthermore, the above effects cannot be easily obtained unless the forging temperature is at least 560°C, preferably at least 580°C with the composition according to the further aspect of the present invention. Thus, the material powder used in the present invention including amorphous promoting elements such as the Fe, X composition or the Fe, Si, X composition can be powder forged at a temperature of at least 560°C. Because powder forging can be carried out at the above-described temperature, the effects of (i), (ii) and (iii) can be easily obtained. The upper limit of the forging temperature is arbitrary as long as the volume ratio of the liquid phase is not more than 10% by volume. Although some liquid phase functions to promote sintering, a liquid phase of more than 10% by volume will lead to the disadvantage of the melted liquid being sputtered out during forging. It is to be noted that forging at a higher temperature causes the structure to become rough, whereby the solidified material is reduced in strength. In order to avoid this problem, heating must be carried out rapidly in a short time. Therefore, the rising speed of the temperature is at least 80°C per minute. A slower rate will cause roughness of the structure. The compositions described in the above two aspects of the present invention are most preferable for effective powder forging with rapid heating at high temperature. More specifically, although the composition according to the one aspect of the present invention includes expensive alloy constituents such as Y and Mm, they are the best alloy composition in view of mechanical characteristics. The composition according to the further aspect of the present invention is economical since expensive element constituents are not included. Furthermore, it has a high amorphous formation ability. The Fe, X composition (X is at least one type selected from Y and Mm), or the Fe, Si, X composition (X is at least one type selected from Ti, Co, Ni, Mn and Cr) are amorphous promoting elements. Among these elements, Fe or Fe and Si are essential elements wherein the necessary lowest amorphous performance is obtained by three or more elements including these essential elements together. It is to be noted that the aluminum powder alloy cannot be easily rendered amorphous if the amount of the above-described elements, i.e. the atomic % of the alloy elements expressed by a and b according to the one aspect of the invention or expressed by a, b and c according to the further aspect of the invention, is below the above-described lower limit. If the atomic % is too high, then the aluminum powder alloy becomes brittle when crystallized. Although all the material powder does not have to be amorphous, a rough intermetallic compound will be crystallized if the alloy composition does not include any amorphous performance. It is therefore necessary to use material powder that has an amorphous phase of at least 1% by volume. Such powder will have a certain level of amorphous performance, and the structure will show a complete solid solution or will be hyperfine of the nano level (the level of a structure of crystal grains and precipitates of nm unit). Conventional ambient chamber heating is not appropriate for rapid heating. In order to suppress roughening of the texture due to forging at high temperature in the present invention, induction heating, resistance heating which are internal heating or infrared radiation heating, laser heating which are surface heating is desirable. The aluminum alloy powder may be not only gas atomized powder, but a combination of at least one type of powder selected from the group consisting of comminuted powder of quenching ribbon, splat cooling powder, melt spinning powder, and mechanical alloy powder. Mish metal is a mixture of a cerium group rare earth element, and is referred to a semifinished product of a refining process. A mish metal generally includes 40-50% Ce by weight and 20-40% La by weight. Mish metal is used because of its low cost. The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWING Fig. 1 is a diagram showing the experiment procedure according to an embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described hereinafter. The following composition in atomic %: (A) Aℓ-Fe 5 - Y 3 (i.e., a composition of 5 atomic % of Fe, 3 atomic % of Y, and the remainder of Aℓ and obligatory impurities) (B) Aℓ - Fe 5.5 - Ti 1.5 - Si 2 (i.e. a composition of 5.5 atomic % of Fe, 1.5 atomic % of Ti, 2 atomic % of Si, and the remainder of Aℓ and obligatory impurities) were powder forged according to the procedure shown in Fig. 1. The values of 0.2% proof stress, elongation after fracture, and the Charpy impact value were examined. Heating was carried out according to the following conditions: (1) Induction heating: increasing temperature rate 100°C/min. (2) General ambient heating chamber (Ar ambient of -45°C of dew point: increasing temperature rate 20°C/min.) (3) Induction heating: increasing temperature rate 50°C min. The results are shown in the following Table 1. It is appreciated from the result of Table 1 that an aluminum alloy of high proof stress and high toughness (the Charpy impact value is at least 20J/cm 2 ) can be obtained by forging solidification according to the powder forging method of the present invention. Thus, according to the powder forging method of the present invention, an aluminum alloy superior in proof stress and toughness can be obtained. It is effective to use the aluminum alloy produced by the powder forging method of the present invention as components for cars and construction members where high proof stress and toughness is required. Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the scope of the present invention being limited only by the terms of the appended claims.

Claims: A method of powder forging aluminum alloy powder of high proof stress and high toughness, comprising the steps of: preparing at least any of aluminum alloy powder and a green compact thereof wherein the general formula of the composition is: Aℓ 100-a-b Fe a X b where a and b in atomic % are: 4.0 ≦ a ≦ 6.0, 1.0 ≦ b ≦ 4.0, and where X is at least one alloy element selected from Y (yttrium) and Mm (mish metal), and an amorphous phase is contained at least 1% by volume; heating at least any of said aluminum alloy powder and said green compact thereof at an increasing temperature rate of at least 80°C per minute to a predetermined temperature of at least 560°C and not more than a temperature at which a liquid phase is contained 10% by volume; and powder forging at least any of said aluminum alloy powder and said green compact thereof at said predetermined temperature. The powder forging method according to claim 1, wherein said predetermined temperature is at least 600°C and not more than a temperature at which a liquid phase is contained 10% by volume. The powder forging method according to claim 1, wherein said step of heating to said predetermined temperature includes heating of at least one method selected from the group consisting of induction heating, resistance heating, infrared radiation heating, and laser heating. The powder forging method according to claim 1, wherein said aluminum alloy powder is prepared from at least one type of powder selected from the group consisting of gas atomized powder, comminuted powder of quenching ribbon, splat cooling powder, melt spinning powder and mechanical alloying powder. A method of powder forging aluminum alloy powder of high proof stress and high toughness, comprising the steps of: preparing at least any of aluminum alloy powder and a green compact thereof wherein the general formula of the composition is: Aℓ 100-a-b-c Fe a Si b X c where a, b and c in atomic % are: 3.0 ≦ a ≦ 6.0, 0.5 ≦ b ≦ 3.0, 0.5 ≦ c ≦ 3.0, and where X is at least one alloy element selected from Ti, Co, Ni, Mn and Cr, and an amorphous phase is contained at least 1% by volume; heating at least any of said aluminum alloy powder and said green compact thereof at an increasing temperature rate of at least 80°C per minute to a predetermined temperature of at least 560°C and not more than a temperature at which a liquid phase is contained 10% by volume; and powder forging at least any of said aluminum alloy powder and said green compact at said predetermined temperature. The powder forging method according to claim 5, wherein said predetermined temperature is at least 580°C and not more than a temperature at which a liquid phase is contained 10% by volume. The powder forging method according to claim 5, wherein said step of heating to a predetermined temperature includes heating of at least one method selected from the group consisting of induction heating, resistance heating, infrared radiation heating and laser heating. The powder forging method according to claim 5, wherein said aluminum alloy powder is prepared from at least one type of powder selected from the group consisting of gas atomized powder, comminuted powder of quench ribbon, splat cooling powder, melt spinning powder and mechanical alloying powder.

Inventors: HORIMURA HIROYUKI, KAJI TOSHIHIKO, MINEMI MASAHIKO, OKAMOTO KENJI, TAKANO YOSHISHIGE, TAKEDA YOSHINOBU, HORIMURA, HIROYUKI, KAJI, TOSHIHIKO, MINEMI, MASAHIKO, OKAMOTO, KENJI, TAKANO, YOSHISHIGE, TAKEDA, YOSHINOBU, HORIMURA, HIROYUKI, C/O KABUSHIKI KAISHA HONDA, KAJI, TOSHIHIKO, C/O ITAMI WORKS OF SUMITOMO, Minemi, Masahiko, c/o Kabushiki Kaisha Honda, OKAMOTO, KENJI, C/O KABUSHIKI KAISHA HONDA, TAKANO, YOSHISHIGE, C/O ITAMI WORKS OF SUMITOMO, TAKEDA, YOSHINOBU, C/O ITAMI WORKS OF SUMITOMO
Applicants: HONDA MOTOR CO LTD, SUMITOMO ELECTRIC INDUSTRIES, HONDA GIKEN KOGYO KABUSHIKI KAISHA, SUMITOMO ELECTRIC INDUSTRIES, LTD.
Application year: 1994
Main classification: B22F3
IPC codes: C22F1, B22F3, C22C45, C22C1, C22C21